CHRYSLER VOYAGER 2005 Service Manual

(14) Measure input shaft end play. Place transaxle
so input shaft is vertical. Set up end play set and
dial indicator as shown in (Fig. 27).Input shaft end
play should be within 0.13-0.64 mm (0.005-0.025
in.)If outside of this range, a #4 thrust plate change
is required. Record indicator reading for reference
upon reassembly.(15) Remove oil pump-to-case bolts (Fig. 28).
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
(16) Install pullers Tool C-3752 as shown in (Fig.
29).
Fig. 26 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 27 Measure Input Shaft End Play Using End
Play Set 8266
1 - TOOL 8266±8
2 - TOOL 8266±2
3 - TOOL C-3339
Fig. 28 Remove Pump Attaching Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 29 Install Tool C-3752
1 - PULLERS TOOL C-3752
2 - PUMP
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41TE AUTOMATIC TRANSAXLE (Continued)

(17) Remove oil pump assembly (Fig. 30) (Fig. 31). (18) Remove oil pump gasket (Fig. 32).
CAUTION: If transaxle failure has occurred, the
cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve.
(19) Remove cooler bypass valve (Fig. 33).
Fig. 30 Remove Oil Pump
1 - ªPUSH INº ON INPUT SHAFT WHILE REMOVING PUMP
Fig. 31 Oil Pump Removed
1 - OIL PUMP
2 - GASKET
Fig. 32 Remove Oil Pump Gasket
1 - PUMP GASKET
Fig. 33 Remove Bypass Valve
1 - COOLER BYPASS VALVE
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41TE AUTOMATIC TRANSAXLE (Continued)

(20) Remove #1 needle bearing (Fig. 34).
(21) Remove input clutch assembly (Fig. 35).(22) Remove #4 thrust plate (Fig. 36).
(23) Remove front sun gear assembly and #4
thrust washer (Fig. 37).
Fig. 34 Remove Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 35 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 36 No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 37 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
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41TE AUTOMATIC TRANSAXLE (Continued)

(24) Remove front carrier/rear annulus assembly
and #6 needle bearing (Fig. 38).
(25) Remove rear sun gear and #7 needle bearing
(Fig. 39).
NOTE: The number 7 needle bearing has three anti-
reversal tabs and is common with the number five
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 40). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.(26) Setup tool 5058 as shown in (Fig. 41). Com-
press 2/4 clutch return spring (just enough to remove
snap ring) and remove snap ring.
NOTE: Verify that Tool 5058 is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
Fig. 38 Remove Front Carrier and Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 39 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 40 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 41 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
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41TE AUTOMATIC TRANSAXLE (Continued)

NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
(27) Remove 2/4 clutch retainer (Fig. 42).
(28) Remove 2/4 clutch return spring (Fig. 43).(29) Remove 2/4 clutch pack (Fig. 44).Tag 2/4
clutch pack for reassembly identification.
(30) Remove tapered snap ring (Fig. 45).
Fig. 42 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 43 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
Fig. 44 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
Fig. 45 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
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41TE AUTOMATIC TRANSAXLE (Continued)

(31) Remove low/reverse reaction plate (Fig. 46).
(32) Remove one low/reverse clutch disc (Fig. 47).(33) Remove low/reverse reaction plate snap ring
(Fig. 48).
(34) Remove low/reverse clutch pack (Fig. 49).
Fig. 46 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 47 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 48 Remove Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 49 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
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41TE AUTOMATIC TRANSAXLE (Continued)

(35) Remove transfer gear cover-to-case bolts (Fig.
50).
(36) Remove transfer gear cover (Fig. 51).(37) Using Tool 6259, remove transfer shaft gear-
to-shaft nut and coned washer (Fig. 52) (Fig. 53).
Fig. 50 Remove Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
Fig. 51 Remove Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPARTATF RTV (MS-GF41) AS SHOWN
Fig. 52 Remove Transfer Shaft Gear Nut
1 - TRANSFER SHAFT GEAR
2 - OUTPUT GEAR
3 - SPECIAL TOOL 6259
Fig. 53 Transfer Shaft Gear Nut and Coned Washer
1 - TRANSFER SHAFT
2 - LOCK WASHER
3 - NUT
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41TE AUTOMATIC TRANSAXLE (Continued)

(38) Using tool L-4407A, remove transfer shaft
gear (Fig. 54).
(39) Remove transfer gear shim (select) (Fig. 55).(40) Remove bearing cup retainer (Fig. 56).
(41) Remove transfer gear bearing cone using
setup shown in (Fig. 57).
Fig. 54 Remove Transfer Shaft Gear
1 - SPECIAL TOOL L4407-6
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A
Fig. 55 Remove Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
Fig. 56 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 57 Remove Transfer Gear Bearing Cone
1 - WRENCHES
2 - TOOL 5048 WITH JAWS TOOL 5048±4 AND BUTTON TOOL
L-4539±2
3 - TRANSFER SHAFT GEAR
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41TE AUTOMATIC TRANSAXLE (Continued)

(42) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 58).
(43) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 59).(44) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 60).
(45) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 61).
Fig. 58 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 59 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 60 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 61 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
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41TE AUTOMATIC TRANSAXLE (Continued)

(46) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 62).
(47) Bend output gear retaining strap ears flat to
allow bolt removal.
(48) Remove output shaft stirrup strap bolts (Fig.
63).(49) Remove stirrup and strap (Fig. 64).
(50) Using Tool 6259 (Fig. 65), remove output shaft
gear-to-shaft bolt and washer (Fig. 66).
Fig. 62 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 63 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 64 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 65 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
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41TE AUTOMATIC TRANSAXLE (Continued)